Methods of manufacturing end effectors for energy-based surgical instruments

ABSTRACT

A method of manufacturing an end effector for a surgical instrument includes providing a substrate wherein at least an outer periphery of the substrate is formed from an electrically-insulative material. The method further includes forming at least one ridge on the outer periphery of the substrate and depositing an electrically-conductive material onto the at least one ridge to form at least one electrode.

BACKGROUND

1. Technical Field

The present disclosure relates to surgical instruments and, moreparticularly, to methods of manufacturing electrosurgical instrumentscapable of electrically treating tissue.

2. Background of Related Art

Various different processes are employed for depositing conductive filmcoatings, or inks, onto a substrate. Such processes include atomic layerchemical vapor deposition, combustion chemical vapor deposition, hotwire chemical vapor deposition, rapid thermal chemical vapor deposition,aerosol assisted chemical vapor deposition, direct liquid injectionchemical vapor deposition, plasma-enhanced chemical vapor deposition,microwave plasma-assisted chemical vapor deposition, laser chemicalvapor deposition, pressurized chemical vapor deposition, vapor phaseepitaxy, cathodic arc deposition, electron beam physical vapordeposition, evaporative physical vapor deposition, pulsed laser physicalvapor deposition, sputter physical vapor deposition, hybridphysical-chemical deposition, and other deposition processes.

More recently, additive manufacturing processes, such as direct-writedeposition, have been developed for accurately depositing complexpatterns and/or architectures of material onto a substrate. Direct-writedeposition, for example, involves the use of a nozzle, or pen-likedevice that is controlled by computer aided design (CAD) software todeposit a specific pattern and/or architecture of material on thesubstrate.

Deposition processes, such as those mentioned above, are commonly usedin semiconductor fabrication, although they also have applicability in awide range of other fields. In particular, the ability to formelectrode(s) by depositing conductive material onto an insulativesubstrate in complex patterns and architectures and/or on substrateshaving various different configurations has found application inenergy-based surgical instrument manufacturing. However, electrosurgicalelectrodes having irregular edges formed during the deposition processmay cause uncontrolled arcing upon application of energy thereto, whichmay ultimately damage the device and/or surrounding tissue.

SUMMARY

As used herein, the term “distal” refers to the portion that is beingdescribed which is further from a user, while the term “proximal” refersto the portion that is being described which is closer to a user.Further, to the extent consistent, any of the aspects described hereinmay be used in conjunction with any of the other aspects describedherein.

In accordance with the present disclosure, a method of manufacturing anend effector for a surgical instrument is provided. The method includesproviding a substrate wherein at least the outer periphery of thesubstrate is formed from an electrically-insulative material. The methodfurther includes forming one or more ridges on the outer periphery ofthe substrate, and depositing an electrically-conductive material ontothe one or more ridges to form one or more electrodes disposed on theouter periphery of the substrate.

In one aspect, the method further includes defining one or morereservoirs adjacent each ridge prior to depositing theelectrically-conductive material onto the ridge.

In another aspect, the electrically-conductive material is deposited onthe one or more ridges via one of direct-write deposition, chemicalvapor deposition, and physical vapor deposition.

In yet another aspect, the substrate is formed wholly from anelectrically-insulative material. Alternatively, the substrate mayinclude an electrically-insulative coating defining the outer peripherythereof.

In still another aspect, one or more cut-outs are defined within thesubstrate to form the one or more ridges.

In another aspect, a plurality of ridges is formed on the outerperiphery of the substrate. The ridges are configured such that a directline-of-sight is established between electrodes of adjacent ridges.

In another aspect, the substrate forms a portion of, or the entire, endeffector of an electrosurgical pencil, jaw member of an electrosurgicalforceps, or other end effector or portion thereof of an energy-basedsurgical instrument.

The method may further include electrically connecting the one or moreelectrodes to a source of energy.

In still yet another aspect, the electrically-conductive material isgold, silver, or another suitable material.

Also provided in accordance with the present disclosure is anothermethod of manufacturing an end effector for a surgical instrument. Themethod includes providing a substrate and forming one or more ridges onthe outer periphery of the substrate. The method further includesforming a reservoir on the outer periphery of the substrate adjacenteach side of the one or more ridges and depositing anelectrically-conductive material onto the one or more ridges such that aportion of the electrically-conductive material overflows the ridge oneither side thereof and is deposited in the reservoirs. Theelectrically-conductive material thus forms one or more electrodesdisposed on the outer periphery of the substrate.

In one aspect, the electrically-conductive material is deposited on theone or more ridges via one of direct-write deposition, chemical vapordeposition, and physical vapor deposition.

In another aspect, a plurality of ridges is formed on the outerperiphery of the substrate. The ridges are configured such that a directline-of-sight is established between electrodes of adjacent ridges.

In yet another aspect, the substrate forms a portion of, or the entire,end effector of an electrosurgical pencil, jaw member of anelectrosurgical forceps, or other end effector or portion thereof of anenergy-based surgical instrument.

In still another aspect, the method further includes electricallyconnecting the one or more electrodes to a source of energy.

Another method of manufacturing an end effector for a surgicalinstrument provided in accordance with the present disclosure includesproviding a substrate and defining one or more cut-outs within an outerperiphery of the substrate to form one or more ridges on the outerperiphery of the substrate. The method further includes depositing anelectrically-conductive material onto the one or more ridges such that aportion of the electrically-conductive material overflows the ridge oneither side thereof. The electrically-conductive material forms one ormore electrodes disposed on the substrate.

In one aspect, the method further includes defining one or morereservoirs adjacent the one or more ridges prior to depositing theelectrically-conductive material onto the one or more ridges.

In another aspect, the electrically-conductive material is deposited onthe one or more ridges via one of direct-write deposition, chemicalvapor deposition, and physical vapor deposition.

In still another aspect, the substrate forms a portion of, or theentire, end effector of an electrosurgical pencil, jaw member of anelectrosurgical forceps, or other end effector or portion thereof of anenergy-based surgical instrument.

In yet another aspect, a plurality of ridges is formed on the outerperiphery of the substrate. The ridges are configured such that a directline-of-sight is established between electrodes of adjacent ridges.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present disclosure are described herein withreference to the drawings wherein like reference numerals identifysimilar or identical elements:

FIG. 1 is a side, perspective view of an electrosurgical pencil providedin accordance with the present disclosure;

FIG. 2 is an enlarged, perspective view of an end effector of theelectrosurgical pencil of FIG. 1;

FIG. 3 is a side, perspective view of an electrosurgical forcepsprovided in accordance with the present disclosure;

FIG. 4 is an enlarged, perspective view of a jaw member of an endeffector of the electrosurgical forceps of FIG. 3;

FIG. 5A is a side view of a blank substrate used in forming the endeffector of the electrosurgical pencil of FIG. 1;

FIG. 5B is a transverse, cross-sectional view taken along section line5B-5B of FIG. 5A;

FIG. 6A is a side view of the substrate of FIG. 5A including ridgesformed on the outer periphery thereof;

FIG. 6B is a transverse, cross-sectional view taken along section line6B-6B of FIG. 6A;

FIG. 6C is an enlarged view of the area of detail indicated in FIG. 6B;

FIG. 7A is a transverse, cross-sectional view taken along section line7A-7A of FIG. 1; and

FIG. 7B is an enlarged view of the area of detail indicated in FIG. 7A.

DETAILED DESCRIPTION

The operating features and inter-cooperating components of energy-basedsurgical instruments 100, 200 provided in accordance with the presentdisclosure are shown in the figures and are described hereinbelow. Morespecifically, although only an electrosurgical pencil 100 (FIGS. 1-2)and an electrosurgical forceps 200 (FIGS. 3-4) are shown, the presentdisclosure is equally applicable for use in conjunction with anyenergy-based surgical instrument having an end effector including one ofmore electrodes configured to conduct energy to tissue to electricallytreat tissue. Obviously, different mechanical and electricalconsiderations apply to each particular type of instrument; however, thenovel aspects with respect to the end effectors and the manufacturethereof remain generally consistent regardless of the particular type ofinstrument used. For the purposes herein, electrosurgical pencil 100(FIGS. 1-2) and electrosurgical forceps 200 (FIGS. 3-4) are generallydescribed.

Referring to FIGS. 1-2 and 7A, electrosurgical pencil 100 includes anelongated housing 102 having an end effector 120 supported therein andextending distally therefrom. End effector 120, as will be describedbelow, includes an electrically-insulative body, or substrate 130 havingone or more electrodes 140, 150, 160 disposed thereon for electricallytreating tissue in either a monopolar or bipolar mode. Electrosurgicalpencil 100 may be coupled to an electrosurgical generator (not shown) orother suitable energy source via a cable 104 or, alternatively, may beconfigured as a battery-powered device incorporating portable power andenergy generating components (not shown) within elongated housing 102.More specifically, transmission wire(s) (not shown) electricallyinterconnect the energy source (not shown) with the electrode(s) 140,150, 160 disposed on end effector 120 at the proximal end of endeffector 120, which extends into elongated housing 102. Similarly,control wires (not shown) electrically interconnect activation switches106, 108, 110 supported on outer surface 112 of housing 102 with theenergy source (not shown).

With continued reference to FIGS. 1-2 and 7A, activation switches 106,108, 110 control the transmission of electrical energy to end effector120 and/or the mode of operation of electrosurgical pencil 100. Forexample, one or more of activation switches 106, 108, 110 may beselectively actuated to one or more depressed positions such that aparticular duty cycle and/or waveform shape is transmitted to one ormore of electrodes 140, 150, 160 of end effector 120 for operation in aparticular mode, e.g., a cutting and/or dissecting mode, a hemostasismode, a combination dissecting and hemostasis mode, or any othersuitable mode for electrically treating tissue as desired. Alternativelyor additionally, one or more of activation switches 106, 108, 110 may beactuated to switch between a monopolar mode of operation and a bipolarmode of operation, and/or to selectively activate one or more ofelectrodes 140, 150, 160 of end effector 120, as desired, toelectrically treat tissue.

Electrosurgical pencil 100 further includes an intensity controller 114slidingly supported on housing 102. Intensity controller 114 includes apair of nubs 116 which are each slidingly supported in a guide channel118 formed in outer surface 112 of housing 102 on either side ofactivation switches 106, 108, 110, although other configurations arealso contemplated. Intensity controller 114 may include a slidepotentiometer (or other suitable intensity-control mechanism) having oneor more positions, e.g., a first position corresponding to a relativelow intensity setting, a second position corresponding to a relativehigh intensity setting, and a plurality of intermediate positionscorresponding to intermediate intensity settings. Intensity controller114 is configured to adjust the power parameters (e.g., voltage, powerand/or current intensity) and/or the power verses impedance curve shapeto affect the perceived output intensity.

Referring still to FIGS. 1-2 and 7A, end effector 120 of electrosurgicalpencil 100 defines a generally elongated substrate 130 formed whollyfrom an electrically-insulative material, having anelectrically-insulative coating or jacket, or otherwise having anelectrically-insulative material disposed about the outer peripherythereof. Elongated substrate 130 defines a generally-cylindricalconfiguration having a rounded distal end 132, although otherconfigurations are also contemplated, and includes one or moreelectrodes 140, 150, 160 disposed thereon that are selectivelyenergizable for treating tissue in various different modes of operation.More specifically, elongated substrate 130 includes: a first electrode140 extending along the generally upwardly-facing surface of substrate130, about curved distal end 132, and along the generallydownward-facing surface of substrate 130 (although the upper and lowerportions of first electrode 140 may alternatively be configured asseparate, independent electrodes); a second electrode 150 disposed onand extending longitudinally along one of the generally-laterally facingsurfaces of substrate 130; and a third electrode 160 disposed on andextending longitudinally along the other generally-laterally facingsurface of substrate 130. Electrodes 140, 150, 160 are disposed onsubstrate 130 in spaced-relation relative to one another wherebysubstrate 130 electrically insulates electrodes 140, 150, 160 from oneanother. Wires (not shown) electrically couple each of electrodes 140,150, 160 to the source of energy (not shown) at the proximal end of endeffector 120, which extends into housing 102, such that the electricalconnections (not shown) are not exposed. Although one configuration ofend effector 120 is shown, it is envisioned that greater or fewerelectrodes and/or other configurations of electrodes 140, 150, 160 or ofsubstrate 130 may be provided, depending on a particular purpose.

In use, in a bipolar mode of operation, for example, first electrode 140may be energized to a first electrical potential, e.g., first electrode140 may be designated as the positive, or active electrode, while secondand third electrodes 150, 160, respectively, are energized to a secondelectrical potential, e.g., second and third electrodes 150, 160,respectively, are designated as the negative, or return electrodes, orvice versa. Electrodes 140, 150, 160 may be energized upon actuation ofone or more of activation switches 106, 108, 110. Once energized, endeffector 120 may be advanced into contact with tissue and/or may beadvanced through tissue to electrically cut tissue, effect hemostasis,and/or otherwise electrically treat tissue. As can be appreciated, endeffector 120 can be operated in various other modes of operation viaselective actuation of one or more of activation switches 106, 108, 110and/or intensity controller 114. Further, depending on the particularmode of operation, one or more of electrodes 140, 150, 160 may beselectively energized to the same potential, different potentials, ormay not be energized.

Turning now to FIGS. 3-4, an electrosurgical forceps 200 is showngenerally including a housing 202, a handle assembly 204, a rotatingassembly 210, a trigger assembly 212, and an end effector 220. Forceps200 further includes a shaft 214 having a distal end 216 configured tomechanically engage end effector 220 and a proximal end 218 thatmechanically engages housing 202. Forceps 200 also includes a cable 280that connects forceps 200 to a generator (not shown) or other suitableenergy source, although forceps 200 may alternatively be configured as abattery powered instrument. Cable 280 includes wires (not shown)extending therethrough that has sufficient length to extend throughshaft 214 in order to provide electrical energy to electrodes 226, 228,240, 250, 260, 270 of end effector 220, e.g., upon selective activationof activation switch 290.

Handle assembly 204 includes a fixed handle 206 and a moveable handle208. Fixed handle 206 is integrally associated with housing 202 andmovable handle 208 is moveable relative to fixed handle 206. Rotatingassembly 210 is rotatable in either direction to rotate end effector 220about a longitudinal axis thereof. Housing 202 houses the internalworking components of forceps 200.

Continuing with reference to FIGS. 3-4, end effector 220 is shownattached at distal end 216 of shaft 214 and includes a pair of opposingjaw members 222, 224. Moveable handle 208 of handle assembly 204 isultimately connected to a drive assembly (not shown) that, together,mechanically cooperate to impart movement of jaw members 222, 224between a spaced-apart position and an approximated position to grasptissue disposed between electrode plates 226, 228 of jaw members 222,224, respectively. As shown in FIG. 3, moveable handle 208 is initiallyspaced-apart from fixed handle 206 and, correspondingly, jaw members222, 224 are in the spaced-apart position. Moveable handle 208 ismovable from this initial position to a depressed position to move jawmembers 222, 224 to the approximated position for grasping tissuetherebetween. End effector 220 is designed as a unilateral assembly,e.g., where jaw member 224 is fixed relative to shaft 214 and jaw member222 is moveable relative to shaft 214 and fixed jaw member 224 (althoughthe reverse configuration is also contemplated). However, end effector220 may alternatively be configured as a bilateral assembly, i.e., whereboth jaw member 222 and jaw member 224 are moveable relative to oneanother and to shaft 214.

With continued reference to FIGS. 3-4, each jaw member 222, 224,respectively, includes an insulative jaw substrate 225, 227, e.g., eachjaw members 222, 225 is wholly formed from an electrically-insulativematerial, has an electrically-insulative coating or jacket disposedabout a frame (not shown) thereof, or otherwise includes anelectrically-insulative material disposed about the outer peripherythereof, and an electrode plate 226, 228 disposed atop, e.g., depositedonto, respective insulative jaw substrate 225, 227 in opposed relationrelative to one another. Electrode plates 226, 228 are adapted toconnect to the energy source (not shown) for conducting energytherebetween and though tissue grasped therebetween to electricallytreat, e.g., seal, tissue. One or both of the jaw members, e.g., jawmember 224, may further include one or more interior electrodes, e.g.,interior electrode 240, disposed on an opposed surface of insulative jawsubstrate 227 of jaw member 224 between jaw members 222, 224. Morespecifically, interior electrode 240 is disposed within a slot 242defined within insulative jaw substrate 227 and electrode plate 228 ofjaw member 224. Interior electrode 240 is electrically insulated fromelectrode plate 228, e.g., via an insulator substrate (not explicitlyshown) disposed within slot 242 and is adapted to connect to the energysource (not shown) for selectively energizing interior electrode 240 toelectrically treat, e.g., electrically cut, tissue grasped between jawmembers 222, 224. When energized, interior electrode 240 may beenergized to a first potential, functioning as the active electrode,while either or both of electrode plates 226, 228 may be energized to asecond, different potential, functioning as return electrodes. Monopolaroperation is also contemplated.

Additionally or alternatively, one or more exterior electrodes, e.g.,first, second, and third exterior electrodes 250, 260, 270,respectively, may be disposed on an outwardly-facing surface ofinsulative jaw substrate 227 of jaw member 224. Exterior electrodes 250,260, 270 are likewise adapted to connect to the energy source (notshown) for conducting energy through tissue to electrically treat, e.g.,dissect, tissue. Exterior electrodes 250, 260, 270 are disposed oninsulative jaw substrate 227 of jaw member 224 and are electricallyinsulated from one another as well as from electrode plates 226, 228 andinterior electrode 240. Exterior electrodes 250, 260, 270 may beconfigured for operation in a bipolar mode, e.g., wherein firstelectrode 250 is energized to a first potential and second and thirdelectrodes 260, 270, respectively, are energized to a second potential.Alternatively, in embodiments where only a single exterior electrode isprovided, the external electrode may be configured to operate in amonopolar mode (or in a bipolar mode wherein electrodes plates 226, 228and/or interior electrode 240 function as the return electrode). Ineither configuration, insulative jaw substrate 227 may function as thesubstrate for receiving electrodes 226, 228, 240, 250, 260, and/or 270thereon, e.g., for deposition of electrodes 226, 228, 240, 250, 260,and/or 270 thereon, or an electrically-insulative material may bedisposed on the jaw frame (not explicitly shown) of either or both ofjaw members 222, 224, e.g., via deposition, for receiving electrodes226, 228, 240, 250, 260, and/or 270 thereon.

Although two exemplary embodiments, e.g., an electrosurgical pencil 100(FIGS. 1-2) and an electrosurgical forceps 200 (FIG. 3) are describedabove, the present disclosure, as mentioned above, is equally applicableto any other suitable surgical instrument having an end effectorincluding one or more electrodes for electrically treat tissue. Withthis in mind, manufacturing methods for forming such end effectors aredescribed in detail below.

Turning now to FIGS. 5A-7B, manufacturing methods provided in accordancewith the present disclosure for forming electrodes 140, 150, 160 onsubstrate 130 of end effector 120 of electrosurgical pencil 100 aredescribed. Although described with respect to end effector 120 ofelectrosurgical pencil 100, the manufacturing methods described hereinare equally applicable for forming any suitable surgical instrument endeffector, or portion thereof, having one or more electrodes forconducting energy to tissue to electrically treat tissue, e.g., themethods described below may similarly be used in the manufacture of jawmember 222 (and/or jaw member 224) of end effector 220 of forceps 200(see FIGS. 3-4), or any other suitable end effector of a surgicalinstrument.

Initially, as shown in FIGS. 5A-5B, the insulative substrate 130 isprovided. Substrate 130, as mentioned above, is formed at leastpartially from an electrically-insulative material. More specifically,substrate 130, may be wholly formed from an electrically-insulativematerial, e.g., ceramic, a biopolymer, or other suitable material, mayinclude an insulative coating or jacket disposed about a frame, e.g., astainless steel frame, or may otherwise include an insulative portionconfigured to receive the electrodes thereon. Substrate 130, includingthe insulative portion thereof, may be formed form any suitable process,e.g., injection-molding, machining, over-molding, mechanical engagement,etc. As shown in FIGS. 5A-5B, the blank substrate 130 defines agenerally cylindrical-shaped configuration having a rounded distal end132, although other configurations are contemplated, depending on theparticular requirements of the surgical instrument being manufacturedand/or the particular procedure to be performed.

Referring to FIGS. 6A-6C, once the blank substrate 130 is formed, orduring formation of the blank substrate 132, a plurality oflongitudinally-extending or otherwise configured cut-outs 134 aredefined within the outer peripheral surface 133 of the blank substrate130, e.g., via machining or other suitable process. Defining cut-outs134 within substrate 130 forms a plurality of longitudinally-extendingridges 136 (or otherwise configured ridges, depending on theconfiguration of cut-outs 134) disposed about the outer periphery ofsubstrate 130. Further, longitudinally-extending (or otherwiseconfigured) reservoirs 138 may be formed adjacent each side of ridges136. That is, a pair reservoirs 138 flanks each ridge 136 (one on eitherside thereof) and likewise flanks each cut-out 134. As will be describedbelow, ridges 136 are configured to receive depositedelectrically-conductive material thereon for forming electrodes 140,150, 160. Thus, cut-outs 134 are defined within substrate 130 to form aparticular configuration of ridges 136 in accordance with the desiredconfiguration of electrodes 140, 150, 160 deposited on substrate 130.That is, although a particular number and configuration of cut-outs 134and corresponding ridges 136 are defined within the outer periphery ofsubstrate 130 in accordance with the desired configuration of theelectrodes 140, 150, 160, cut-outs 134 may be defined within substrate130 in any suitable number and/or configuration so as to define anyconfiguration of ridges 136 in accordance with the desired configurationof electrodes 140, 150, 160 to be disposed on substrate 130.

Although substrate 130 is shown including ridges 136 (and reservoirs138) defining generally squared-off configurations, other suitablesizes, shapes, and/or configurations are also contemplated. However,regardless of the configuration of ridges 136, it is envisioned thatridges 136 are formed such that a direct line-of-sight “K” (FIG. 7A) isestablished between the electrodes formed about adjacent ridges 136.Such a feature is particularly relevant when dealing with curved orother non-planar substrate surfaces, e.g., the surface of generallycylindrically-shaped substrate 130. The exact configuration, e.g.,height, shape, etc., of ridges 136 necessary to establish theseline-of-sights “K” depends on the shape of the substrate surface, thedistance between the ridges, the thickness of the electrode to bedeposited thereon, and other factors.

Referring now to FIGS. 7A-7B, once cut-outs 134 and reservoirs 138 havebeen defined within substrate 130 to form ridges 136 a, 136 b, 136 c,136 d (collectively ridges 136), the electrically-conductive material isdisposed on each ridge 136 a, 136 b, 136 c, 136 d to form electrodes140, 150, 160. That is, first electrode 140, which extends along boththe upper and lower-facing surfaces of substrate 130 and about roundeddistal end 132 (see FIG. 6A) thereof, is formed via depositingelectrically-conductive material onto ridges 136 a and 136 c, whilesecond and third electrodes 150, 160, respectively, are formed viadepositing electrically-conductive material onto ridges 136 b and 136 d,respectively. The electrically-conductive material may include silverink, gold ink, or other suitable material and may be deposited ontoridges 136 via direct-write deposition, physical vapor deposition,chemical vapor deposition, or any other suitable deposition process.Upon deposition of the electrically-conductive material onto ridges 136,rather than producing irregular edges, as may result when depositing ona smooth surface, ridges 136 allow at least some of the material tooverflow ridges 136 such that at least some of the material extends overthe sides of ridges 136 and, in embodiments where provided, is collectedby reservoirs 138. As a result of this configuration, the electrodes140, 150, 160 define smooth and consistent edges extending along theedges of ridges 136, with any excess material overflowing ridges 136 andextending down the side walls of ridges 136 into reservoirs 138, asshown in FIGS. 7A-7B.

One particular direct-write deposition technique that may be employedfor depositing the electrically-conductive material onto ridges 136 isMICROPEN® Technologies' MICROPENNING®. MICROPENNING® is amicro-capillary technology that uses a positive displacement method ofpumping flowable materials, typically having a viscosity of betweenabout 5 and about 500,000 centipoise, onto a surface. MICROPENNING® maybe used to control the volume of flowable material (e.g.,electrically-conductive ink) applied, thus providing the capability todeposit one or more smooth, consistent layers of material onto ridges136. However, despite, the precision of MICROPENNING®, the formation ofirregular edges may still occur and, thus, it is the use ofMICROPENNING® in conjunction with ridges 136 (and reservoirs 138) thatpermits the formation of electrodes that having smooth, consistentsurfaces without irregular edges.

As mentioned above, ridges 136 are formed on substrate 130 such that,upon deposition of electrodes 140, 150, 160 onto ridges 136, a directline-of-sight “K” is established between adjacent electrodes, e.g., theupper portion of electrode 140 and electrodes 150, 160 on either sidethereof, and the lower portion of electrode 140 and electrodes 150, 160on either side thereof. As can be appreciated, the increased elevationof ridges 136 relative to outer peripheral surface 133 of substrate 130allows for these direct line-of-sights “K,” rather than havingelectrodes 140, 150, 160 hidden from one via substrate 130, e.g., overthe horizon of the cylindrically-shaped substrate 130. It has been foundthat providing a direct line-of-sight “K” between adjacent electrodesadapted to conduct energy therebetween, e.g., from positive electrode140 to negative electrodes 150, 160, facilitates the treatment of tissueat least by helping to ensure that both the positive and negativeelectrodes sufficiently contact tissue.

Referring to FIGS. 1-2 and 7A-7B, with the electrodes 140, 150, 160formed on substrate 130, the proximal end of end effector 120 (FIG. 1)may be engaged within housing 102, the proximal ends of electrodes 140,150, 160 may be coupled to the energy source (not shown), e.g., viawires and suitable electrical connections (not shown), andelectrosurgical pencil 100 may be otherwise assembled to complete themanufacture thereof.

As can be appreciated, although described with respect to end effector120, the above-described manufacturing process may be used for themanufacture of any suitable surgical instrument wherein electrodes aredisposed on a substrate. That is, the above-describe methods generallyremain the same regardless of the specific configuration of the surgicalinstrument, namely: the substrate is provided; cut-outs and, if desired,reservoirs are defined within the outer periphery of the substrate todefine ridges thereon corresponding to the desired positions of theelectrodes; and an electrically-conductive material is deposited ontothe ridges to form the electrodes while reducing the occurrence ofirregular edges, thus reducing the likelihood of arcing upon applicationof energy to the electrodes to treat tissue.

While several embodiments of the disclosure have been shown in thedrawings, it is not intended that the disclosure be limited thereto, asit is intended that the disclosure be as broad in scope as the art willallow and that the specification be read likewise. Therefore, the abovedescription should not be construed as limiting, but merely asexemplifications of particular embodiments. Those skilled in the artwill envision other modifications within the scope and spirit of theclaims appended hereto.

What is claimed is:
 1. A method of manufacturing an end effector for asurgical instrument, comprising: providing a substrate, at least anouter periphery of the substrate formed from an electrically-insulativematerial; forming at least one ridge on the substrate; forming areservoir within the substrate adjacent each side of the at least oneridge; and depositing an electrically-conductive material onto the atleast one ridge such that the electrically-conductive material surroundsthe at least one ridge and overflows the at least one ridge into thereservoirs to form at least one electrode, and such that theelectrically-insulative outer periphery of the substrate is exposed oneither side of the at least one electrode to electrically-isolate the atleast one electrode.
 2. The method according to claim 1, wherein theelectrically-conductive material is deposited on the at least one ridgevia one of: direct-write deposition, chemical vapor deposition, andphysical vapor deposition.
 3. The method according to claim 1, whereinthe substrate is formed wholly from an electrically-insulative material.4. The method according to claim 1, wherein the substrate includes anelectrically-insulative coating defining the outer periphery thereof. 5.The method according to claim 1, wherein at least one cut-out is definedon the outer periphery of the substrate to form the at least one ridge.6. The method according to claim 1, wherein a plurality of ridges isformed on the outer periphery of the substrate, the ridges configuredsuch that a direct line-of-sight is established between electrodes ofadjacent ridges.
 7. The method according to claim 1, wherein thesubstrate forms at least a portion of one of an end effector of anelectrosurgical pencil and a jaw member of an electrosurgical forceps.8. The method according to claim 1, wherein the electrically-conductivematerial is one of gold and silver.
 9. The method according to claim 1,further comprising electrically connecting the at least one electrode toa source of energy.
 10. A method of manufacturing an end effector for asurgical instrument, comprising: providing a substrate having anelectrically-insulative outer periphery; forming at least one ridge onthe substrate; forming a plurality of reservoirs within the substrate,the plurality of reservoirs disposed such that a reservoir is locatedadjacent each side of the at least one ridge; and depositing anelectrically-conductive material onto the at least one ridge such that aportion of the electrically-conductive material overflows the ridge oneither side thereof and is deposited in the plurality of reservoirs tosurround the at least one ridge and form at least one electrode, theplurality of reservoirs collecting the overflow electrically-conductivematerial such that the electrically-insulative outer periphery of thesubstrate is exposed on either side of the at least one electrode toelectrically-isolate the at least one electrode.
 11. The methodaccording to claim 10, wherein the electrically-conductive material isdeposited on the at least one ridge via one of: direct-write deposition,chemical vapor deposition, and physical vapor deposition.
 12. The methodaccording to claim 10, wherein a plurality of ridges is formed on theouter periphery of the substrate, the ridges configured such that adirect line-of-sight is established between electrodes of adjacentridges.
 13. The method according to claim 10, wherein the substrateforms at least a portion of one of an end effector of an electrosurgicalpencil and a jaw member of an electrosurgical forceps.
 14. The methodaccording to claim 10, further comprising electrically connecting the atleast one electrode to a source of energy.
 15. A method of manufacturingan end effector for a surgical instrument, comprising: providing anelectrically-insulative substrate; forming a plurality of cut-outswithin the electrically-insulative substrate to form at least one ridge,the at least one ridge disposed between two of the cut-outs, eachcut-out defining a cut-out surface on the outer periphery of thesubstrate; and depositing an electrically-conductive material onto theat least one ridge such that a portion of the electrically-conductivematerial overflows the ridge on either side thereof to surround theridge and form at least one electrode, and such that the cut-outsurfaces are exposed on either side of the at least one electrode toelectrically-isolate the at least one electrode.
 16. The methodaccording to claim 15, further comprising forming a reservoir within thecut-out surface of the substrate adjacent each side of the at least oneridge prior to depositing the electrically-conductive material onto theat least one ridge, wherein a portion of the electrically-conductivematerial overflows the at least one ridge into the reservoirs.
 17. Themethod according to claim 15, wherein the electrically-conductivematerial is deposited on the at least one ridge via one of: direct-writedeposition, chemical vapor deposition, and physical vapor deposition.18. The method according to claim 15, wherein the substrate forms atleast a portion of one of an end effector of an electrosurgical penciland a jaw member of an electrosurgical forceps.
 19. The method accordingto claim 15, wherein a plurality of ridges is formed on the outerperiphery of the substrate, the ridges configured such that a directline-of-sight is established between electrodes of adjacent ridges.